Package having flexible edge protection

ABSTRACT

A package for a roll having flexible edge protection including at least one protective end cap adjacent one end of the roll and an outer cylindrical film layer surrounding the outer roll surface. The flexible edge cap and the cylindrical film layer form the flexible edge protection package.

RELATED APPLICATIONS

[0001] The present application is related to Provisional Application Ser. No. 60/182,806 filed Feb. 16, 2000; Provisional Application Ser. No. 60/182,808 filed Feb. 16, 2000; and Provisional Application Ser. No. 60/225,243 filed Aug. 15, 2000.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to a package which is flexible and includes flexible edge protection.

[0003] Packages for rolls are well known in the art. U.S. Pat. Nos. 5,850,918 and 5,890,591 disclose packages. These patents disclose packages which utilize axial wraps and radial wraps. An axial wrap, for the purpose of this patent application, includes a layer of film material which is wrapped parallel to the core or the longitudinal center line of the roll. In some situations, a radial wrap is also used. For the purposes of this patent application, a radial wrap is a film layer which is wrapped in a direction perpendicular to the core or the longitudinal centerline of the roll. In some embodiments, the radial wrap is in a direction generally perpendicular to the longitudinal centerline. A spiral wrap is an example of this type of a radial wrap.

[0004] The prior art patents also disclose the use of a header or disk positioned adjacent the ends of the rolls. Often, the header is manufactured from protective cardboard materials.

[0005] U.S. Pat. No. 5,346,067 discloses a package for an object. The package includes a core which receives rectangular shaped end pieces or end pieces that have a square cross section.

SUMMARY OF THE INVENTION

[0006] The present invention is directed to a package with flexible edge protection for use with a variety of rolls. The package includes at least one protective end cap adjacent one end of the roll and an outer cylindrical film layer surrounding the outer roll surface. The flexible edge cap and the cylindrical film layer form the flexible edge protection package.

[0007] Other objects and advantages of the present invention will become apparent to those skilled in the art upon review of the following description of the preferred embodiment and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is a perspective view of a roll package, according to the present invention;

[0009]FIG. 2 is a fragmentary, enlarged, cross-sectional view taken along the line 2-2 of FIG. 1;

[0010]FIG. 3 is a perspective view, similar to FIG. 1, showing another embodiment of a roll package according to the present invention;

[0011]FIG. 4 is a perspective view, similar to FIG. 1, showing still another embodiment of a roll package, according to the present invention;

[0012]FIG. 5 is a fragmentary, enlarged, cross-sectional view taken along the line 5-5 of FIG. 4;

[0013]FIG. 6 is a perspective view, similar to FIG. 4, of a still further embodiment of the present invention;

[0014]FIG. 7 is a perspective view, similar to FIG. 1, showing another embodiment of a roll package, according to the present invention;

[0015]FIG. 8 is a fragmentary, enlarged, cross-section view taken along the line 8-8 of FIG. 7;

[0016]FIG. 9 is a perspective view, similar to FIG. 7, showing a still further embodiment of a roll package, according to the present invention;

[0017]FIG. 10 is a perspective view, similar to FIG. 1, showing another embodiment of a roll package according to the present invention with a portion broken away to show a header;

[0018]FIG. 11 is a fragmentary, enlarged, cross-section view taken along the line 11-11 of FIG. 10;

[0019]FIG. 12 is a perspective view, similar to FIG. 10 of another embodiment of a roll package, according to the present invention, with portions broken away to show headers adjacent the opposite ends of the roll;

[0020]FIG. 13 is a perspective view, similar to FIG. 1, showing a still further embodiment of a roll package, according to the present invention;

[0021]FIG. 14 is a fragmentary, enlarged, cross-section view taken along the line 14-14 of FIG. 13; and

[0022]FIG. 15 is a perspective view, similar to FIG. 13 of another embodiment of a roll package, according to the present invention, with portions broken away to show headers at opposite ends of the roll.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] The preferred embodiments and the best mode of the present invention will now be described in detail with reference being made to the accompanying drawings.

[0024] Referring to FIG. 1, a package, according to the present invention is generally indicated by the reference number 20. The roll 21 is a cylindrical roll having an outer cylindrical surface 22 and opposed roll ends 23.

[0025] The package 20 is used to cover or enclose a roll 21. In a preferred embodiment, the roll 21 is a cylindrical paper roll. However, the roll 21 can be a variety of roll products including, for examples, paper rolls, metal rolls, plastic rolls, fibrous material rolls or non-woven roll materials. The roll 21 can also comprise cable-like product rolls, for examples, fiber optic cables, cooper wires, aluminum wires, and similar wound products.

[0026] The package 20 includes a flexible edge cap 24 having a ring shaped base 25 and an integral cylindrical side wall 26 extending from the ring shaped base 25. The package 20 also includes a cylindrical film layer 27 positioned over the outer cylindrical surface 22 of the roll 21. The film layer 27-27; in each of the following is preferably constructed of plastic flexible film and normally having a thickness between 60 gauge and 300 gauge. The plastic film 27 is normally a polyethylene film. The film layer 27 and the edge cap 24 form or define the flexible edge protection package 20.

[0027] The flexible edge cap 24-24; is a polyolefin material having the ability to be elongated and to retain tensile holding force while being flexed thereby increasing or decreasing in length. In a preferred embodiment, the flexible edge protection material defining the cap 24 is a polyethylene having a thickness in the range of about 5 mil. to about 100 mil. and having a width or diameter in the range from about 2 inches to about 100 inches. The film layer 27 is positioned either under or over, or both under and over the flexible edge protection polyethylene material layer or layers which define the edge cap 24. In addition, the film layer 27 can be positioned over the roll 21 either axially or radially, or both axially and radially.

[0028] Referring to FIG. 3, another embodiment of a package, according to the present invention is generally indicated by the reference number 30. The package 30 is similar to the package 20 illustrated in FIGS. 1 and 2 with the exception that a flexible edge cap 24 a is positioned adjacent each of the roll ends 23 a. A cylindrical film layer 27 a is wrapped on the outer cylindrical roll surface. The pair of flexible edge caps 24 a and the film layer 27 a form the overall flexible edge protection package 30.

[0029] Another roll package, according the present invention is generally indicated in FIGS. 4 and 5 by the reference number 35. The package 35 is similar to the package 20. A flexible edge cap 24 b is mounted adjacent a roll end 23 b of a roll 21 b. The flexible edge cap 24 b includes a ring shaped base 25 b and an integral cylindrical side wall 26 b extending from the base 25 b. The package 35 includes a flexible film layer, which in the present embodiment is a radial wrapped layer 27 b. The radial wrapped layer 27 b normally consists of multiple wraps and extends both over the cylindrical outer surface 22 b of the roll 21 b and also over the cylindrical side wall 26 b and the ring shaped base 21 defining the flexible edge cap 24 a, as best shown in FIG. 5.

[0030] Referring to FIG. 6, still another embodiment of a package, according to the present invention is generally indicated by the reference number 40. The package 40 is similar to the package 35 illustrated in FIGS. 4 and 5. However, the package 40 includes two flexible end caps 24 c located adjacent the roll ends 23 c of the roll 21 c. The package 40 includes both the flexible edge caps 24 c and a radial wrapped flexible film layer 27 c forming the overall flexible edge protection package 40.

[0031] Referring to FIGS. 7 and 8, another embodiment of a roll package, according to the present invention is generally indicated by the reference number 45. The roll package 45 includes a flexible edge cap 24 d mounted adjacent one of the roll ends 23 d of the roll 21 d. The flexible edge cap 24 d includes a ring shaped base 25 d and a cylindrical side wall 26 d extending from the base 25 d. A film layer 27 a is positioned over the outer cylindrical surface 22 d of the roll 21 d and also over the flexible edge cap 24 a and the roll end 23 d. In the present embodiment, the film layer 27 d includes multiple wraps. As illustrated by dashed lines in FIG. 7, the film layer 27 d includes a first multiple wrapped portion 46 which is applied as an axial wrap over the outer cylindrical surface 22 d and over the roll ends 23 d. The film layer 27 d of the package 45 also includes a second multiple wrap portion 47 which is applied as a radial wrap. In the present embodiment the second multiple wrap portion 47 is applied as a spiral wrap. The package 45 therefore includes the flexible edge cap 24 d and the flexible cylindrical film layer 27 d which is composed of the first multiple wrap portion 46 and the second multiple wrap portion 47.

[0032] Referring to FIG. 9, another embodiment of the present invention is generally indicated by the reference number 50. The package 50 has the same construction of as the package 45 with the exception that two flexible edge caps 24 e are included in the package 50. The package 50 also includes a flexible film layer 27 e composed of an axial wrap portion 46 e and a radial wrap portion 47 e. A flexible edge cap 24 e is mounted adjacent each of the opposed roll ends 23 e of the roll 21 e.

[0033] Referring to FIGS. 10 and 11, another embodiment of a package according to the present invention is generally indicated by the reference number 55. The package 55 is similar to the package 45 illustrated in FIGS. 7 and 8 and described above. However, in the package 55 a circular header or disk 56 is mounted adjacent the roll end 23 f of the roll 21 f. The header 56 is constructed of cardboard, which adds further protection to the roll 21 f. However, the header 56 may be constructed of other materials such as paper products or plastic foam materials. As best shown in FIG. 11, a flexible edge cap 24 f is positioned over the header 56 and over the outer cylindrical surface 22 f of the roll 21 f. A flexible film layer 27 f including a first multiple wrap portion 46 f and a second multiple wrap portion 47 f is positioned over the outer cylindrical roll surface 22 f and the flexible edge cap 24 f thereby defining or forming the flexible edge protection package 55. The first multiple wrap portion 46 f is an axial wrap, generally parallel to the longitudinal axis of the roll 21 f, and the second multiple wrap portion 47 f is a radial wrap, which is applied generally perpendicular to the longitudinal axis of the roll 21 f.

[0034] Referring to FIG. 12, another embodiment of a package according to the present invention is generally indicated by the reference number 60. The package 60 is identical with the package 55 illustrated in FIGS. 10 and 11, described above with the exception that a flexible edge cap 24 g is positioned adjacent both of the opposed roll ends 23 g of the roll 21 g. As best illustrated by the broken away portions of FIG. 12, a circular header 56 g is mounted adjacent both of the roll ends 23 g of the roll 21 g. The flexible edge caps 24 g are positioned over the headers 56 and in turn are covered by the flexible film layer 27 g comprised of a first multiple wrap portion 46 g and a second multiple wrap portion 47 g.

[0035] A still further embodiment of a package, according to the present invention is indicated by the reference number 65 in FIGS. 13 and 14. The package 65 has a construction similar to the package 35 illustrated in FIGS. 4 and 5 and described above. However, the package 65 includes a header 56 h positioned adjacent a roll end 23 h of a roll 21 h. A flexible edge cap 24 h is mounted over the header 56 h with its side wall 26 h extending over a portion of the outer cylindrical surface 22 h of the roll 21 h. In the present embodiment, a film layer 27 h is a multi-wrap polyethylene film layer. The film layer 27 h is radially applied.

[0036] Referring to FIG. 15, a still further embodiment of a package, according to the present invention is generally indicated by the reference number 70. The package 70 is identical with the package 65 illustrated in FIGS. 13 and 14 with the exception that a header 56 i is applied adjacent both of the opposed roll ends 23 i of the roll 21 i. The package 70 includes flexible edge caps 24 i mounted adjacent both of the roll ends 23 i and a flexible multiple wrap film layer 27 i.

[0037] Numerous modifications may be made to the preferred embodiments of the package described above without departing from the scope of the present invention or from the following claims. 

I claim:
 1. A package for a roll, the roll having an outer cylindrical roll surface and opposed roll ends, said package including at least one flexible edge cap, said edge cap being cup shaped for receiving and protecting the circular edge defined by the intersection of the cylindrical roll surface and an adjacent roll end, said package including a cylindrical film layer surrounding said outer cylindrical roll surface, said flexible edge cap and said cylindrical film layer forming the flexible edge protection package.
 2. A package, according to claim 1 , wherein a flexible edge cap is positioned adjacent each end of such roll.
 3. A package, according to claim 1 , wherein said flexible edge cap has a ring shaped base and a cylindrical side wall extending from said ring shaped base.
 4. A package, according to claim 1 , wherein said cylindrical film layer comprises polyolefin film layers.
 5. A package, according to claim 4 , wherein said polyolefin film has a thickness between 60 gauge and 300 gauge.
 6. A package, according to claim 1 , wherein said cylindrical film layer is radially wrapped over such outer cylindrical roll surface.
 7. A package, according to claim 1 , wherein said cylindrical film layer is axially wrapped over such outer cylindrical roll surface.
 8. A package, according to claim 1 , wherein said cylindrical film layer includes a first multiple axial wrap portion and a second multiple radially wrap portion. 